M38 Dana 18 transfer case

Brumbach · Post by **Brumbach** » Mon Apr 25, 2016 2:38 pm

Aside from minor repairs to the park brake, I'm attempting to repaint the transfer case. I've cleaned it up and now steel wheeling the remaining surface rust. Is it possible to remove the park brake and shifting assembly without tearing into the transfer case? It appears I'll have to remove the 1 1/4 nut and use a puller to take off the park brake. Any thing else there? As for the shift tower, I've removed the attaching bolts but it will only pull out a short distance. What's holding it? Help!

Thanks,

Bill

southpw · Post by **southpw** » Mon Apr 25, 2016 7:11 pm

You can remove the rear nut and remove the parking brake assembly without any issues. Mine came apart without needing much more than a rubber mallet to remove.
With the bolts removed from shifter cover, mine pulled right off. The shifters have 2 forks that engage inside the case. Maybe its getting hung up around one of the forks. Have you tried removing cover with shifter in different positions?

Brumbach · Post by **Brumbach** » Tue Apr 26, 2016 6:58 am

southpw wrote:You can remove the rear nut and remove the parking brake assembly without any issues. Mine came apart without needing much more than a rubber mallet to remove.
With the bolts removed from shifter cover, mine pulled right off. The shifters have 2 forks that engage inside the case. Maybe its getting hung up around one of the forks. Have you tried removing cover with shifter in different positions?

I haven't but will. Thanks

Post by **wesk** » Tue Apr 26, 2016 10:01 am

Look on our web links page for the Dana 18 rebuild site and you'll get some very useful info there. It's Rick Stiver's Dana 18 blow by blow rebuild.

Under the Technical/How To list:
http://www.willysmjeeps.com/v2/modules. ... link&cid=9

Brumbach · Post by **Brumbach** » Tue Apr 26, 2016 4:07 pm

Is the Dana 18 for the M38 equipped with the 3/4", 1 1/8" or 1 1/4" intermediate shaft? I'll bet 1 1/8". Thanks

Brumbach · Post by **Brumbach** » Tue Apr 26, 2016 4:35 pm

wesk wrote:Look on our web links page for the Dana 18 rebuild site and you'll get some very useful info there. It's Rick Stiver's Dana 18 blow by blow rebuild.

Under the Technical/How To list:
http://www.willysmjeeps.com/v2/modules. ... link&cid=9

Got it done. Thanks

southpw · Post by **southpw** » Tue Apr 26, 2016 4:36 pm

You can measure it on the outside of the case. Im not sure when they made the changes to the shafts. Not sure either one of my D18's are original. One is 1.125, the other 1.25 so i chose the 1.25" one to rebuild.

Brumbach · Post by **Brumbach** » Tue Apr 26, 2016 4:47 pm

southpw wrote:You can measure it on the outside of the case. Im not sure when they made the changes to the shafts. Not sure either one of my D18's are original. One is 1.125, the other 1.25 so i chose the 1.25" one to rebuild.

My mic is reading 1.14 but I'm old and unsteady so I'm guessing it's 1.125. But then again, isn't that the fat end which would be larger than 1.125? That's why I asked. Don't want to order the wrong gasket kit.